U.S. patent application number 14/450296 was filed with the patent office on 2016-02-04 for geopolymer brick fabrication system.
This patent application is currently assigned to UNIVERSITI MALAYSIA PERLIS. The applicant listed for this patent is KING ABDUL AZIZ CITY SCIENCE & TECHNOLOGY (KACST). Invention is credited to MOHD MUSTAFA AL BAKRI ABDULLAH, MUHD IZZAT AHMAD, MOHAMMED BINHUSSAIN, CHE MOHD RUZAIDI GHAZALI, KAMARUDIN HUSSIN, WAN MASTURA WAN IBRAHIM, KHAIRUL NIZAR ISMAIL, MOHAMMAD TAMIZI SELIMIN, MUHAMMAD FAHEEM MOHD TAHIR.
Application Number | 20160031117 14/450296 |
Document ID | / |
Family ID | 55179104 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160031117 |
Kind Code |
A1 |
ABDULLAH; MOHD MUSTAFA AL BAKRI ;
et al. |
February 4, 2016 |
GEOPOLYMER BRICK FABRICATION SYSTEM
Abstract
A geopolymer brick fabrication system comprising a mixer (100)
having a tank (101) which comprises a closeable bottom outlet (102)
and an inner surface coated with saturated polyester resin that is
resistant against corrosive geopolymeric material for receiving the
geopolymer raw material to be mixed by shaft (103) driven by a
spindle motor (104) a moulding section (200) to receive the mixed
geopolymer raw material through a slanted conveyer (105) upon
opening of the closeable outlet (102) for shaping the mixture under
pressure inside a mould (201) to obtain a geopolymer brick and a
curing section (300) having a moving platform (301) across a curing
chamber (302) to simultaneously cure and transport the brick
thereon.
Inventors: |
ABDULLAH; MOHD MUSTAFA AL
BAKRI; (KANGAR, MY) ; TAHIR; MUHAMMAD FAHEEM
MOHD; (KANGAR, MY) ; HUSSIN; KAMARUDIN;
(KANGAR, MY) ; SELIMIN; MOHAMMAD TAMIZI; (KANGAR,
MY) ; IBRAHIM; WAN MASTURA WAN; (KANGAR, MY) ;
AHMAD; MUHD IZZAT; (KANGAR, MY) ; GHAZALI; CHE MOHD
RUZAIDI; (KANGAR, MY) ; ISMAIL; KHAIRUL NIZAR;
(KANGAR, MY) ; BINHUSSAIN; MOHAMMED; (RIYADH,
SA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KING ABDUL AZIZ CITY SCIENCE & TECHNOLOGY (KACST) |
Riyadh |
|
SA |
|
|
Assignee: |
UNIVERSITI MALAYSIA PERLIS
KANGAR
MY
KING ABDUL AZIZ CITY SCIENCE & TECHNOLOGY (KACST)
RIYADH
SA
|
Family ID: |
55179104 |
Appl. No.: |
14/450296 |
Filed: |
August 4, 2014 |
Current U.S.
Class: |
425/200 |
Current CPC
Class: |
B28C 5/12 20130101; B28B
15/00 20130101; Y02P 40/10 20151101; C04B 28/006 20130101; Y02P
40/165 20151101; C04B 12/005 20130101 |
International
Class: |
B28B 1/14 20060101
B28B001/14; B28B 17/02 20060101 B28B017/02; B28B 11/24 20060101
B28B011/24; B28B 13/06 20060101 B28B013/06 |
Claims
1. A geopolymer brick fabrication system comprising: a mixer (100)
having a tank (101) which comprises a closeable bottom outlet (102)
and an inner surface coated with saturated polyester resin that is
resistant against corrosive geopolymeric material for receiving the
geopolymer raw material to be mixed by shaft (103) driven by a
spindle motor (104); a moulding section (200) to receive the mixed
geopolymer raw material through a slanted conveyer (105) upon
opening of the closeable outlet (102) for shaping the mixture under
pressure inside a mould (201) to obtain a geopolymer brick; and a
curing section (300) having a moving platform (301) across a curing
chamber (302) to simultaneously cure and transport the brick
thereon.
2. A system according to claim 1, wherein the tank (101) is having
a mixing capacity in a range from 40 to 200 kg of geopolymer raw
material.
3. A system according to claim 1, wherein the mixer (100) further
comprises a movable frame structure (106).
4. A system according to claim 1, wherein the moulding section
(200) is having an ejector (204) beneath the mould (201) to release
the brick therefrom.
5. A system according to claim 1 further comprising an extension
conveyer (400) between the moulding section (200) and the curing
section (300).
6. A system according to claim 1 further comprising a controller
(303) attaching to the curing chamber to regulate operation of the
system.
7. A system according to claim 1 further comprising a gravity
roller conveyer (501).
8. A system according to claim 1, wherein the geopolymer raw
material comprising a combination of pozzolanic material, alkaline
activator and aggregate.
9. A system according to claim 8, wherein the pozzolanic material
is derived from fly ash, volcanic ash, palm oil fly ash or a
combination thereof.
Description
FIELD OF INVENTION
[0001] This present invention relates to a system to fabricate
geopolymer brick. In particular, the system comprises a mixer
having a tank coated with saturated polyester resin, a moulding
section and a curing section which are interconnected with
conveyers to deliver or receive the products therefrom.
BACKGROUND OF THE INVENTION
[0002] Bricks are blocks or a single unit of a ceramic material
used in masonry construction. It is essentially made from clay,
lime-and-sand, concrete or shaped stone. Common methods in
producing a brick comprises mixing the raw ingredients with water,
pressing and fired to achieve strength. To obtain a consistent
brick product, the bricks are often fired in tunnel kiln having
conveyers, rails or kiln cars. Often, the composition of raw
ingredients are adjusted to accelerate the burning process.
[0003] A China Patent No. CN101941825A has disclosed a
manufacturing method of an environmental friendly brick from
combustion slag of oil-bearing sludge. The method of manufacturing
comprises mixing, extrusion molding in a mechanical vibration mode,
steam-curing and cooling the produced brick naturally.
[0004] Another China Patent No. CN101913842A reveals a
manufacturing method of a baked light-weight environmental friendly
bricks prepared from paper mill sludge. The method comprises mixing
the materials with water, extruding the damp product, molding with
a blank cutter, pressing and naturally drying the for 7 days.
Finally, the air-dried bricks are baked in a tunnel kiln for a
finished product.
[0005] Nevertheless, the bricks in the prior arts above mainly
comprises water, or a treatment using steam. This is due to the
usage of cement which requires a hydration step to impart binding
properties with other raw materials of a brick. Consequently, the
brick is able to harden and solidify upon demoulding.
[0006] Geopolymer has been widely used as an alternative source of
cement in brick making industry. Geopolymer bricks are essentially
made from aluminosilicate material. In a highly alkaline
environment, silicon hydroxides and aluminium hydroxides are
released from the material. Subsequently, polycondensation reaction
leads to solidification, whereby an aluminosilicate tetrahedral
polymer network is formed. Recently, pozzolan or pozzolanic
material has been gaining popularity to act as aluminosilicate
material in an alkaline medium. Beside the choice of geopolymer
material to be used, the ratio of each material, the homogeneity in
the material mixture, the hardening or curing condition could also
affect the integrity of the produced geopolymer brick.
[0007] A U.S. Patent No. US2012255462 A1 discloses a production of
geopolymers from oil shale, mineral residues or a combination
thereof. However, the prior art merely discloses the method of
producing such geopolymer which comprises pretreatment of the oil
shale, mixing, hardening and demoulding the geopolymer. The mixture
is presented and also transported between stages in its slurry form
until it reaches the hardening stage. Hence, more than a mould is
necessary to hold the slurry before it is hardened. Further, a
demoulding stage is required to retrieve the mould.
[0008] Nevertheless, most patented technologies emphasize on the
composition and choice of geopolymer material in preparation of
geopolymer. Hence, a system for batch production of geopolymer
brick is desired to withstand high alkaline environment of
geopolymer material.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is to provide a system
for batch production of geopolymer brick. In one of the preferred
embodiment, the system is able to process 40 to 200 kg of
geopolymer raw material in a batch.
[0010] The object of the invention is to provide a system having a
motor-driven mixer to produce homogeneous geopolymer raw material
mixture.
[0011] One of the object of the invention is to provide a system
comprising a mixer having a tank coated with saturated polyester
resin to be resistant against high alkaline condition provided by
the geopolymer raw material.
[0012] One of the object of the invention is to provide a system
which is able to produce quality geopolymer bricks. In the
preferred embodiment, the bricks are cured on a moving platform
across a curing chamber. Hence, heat applied in the curing section
is essentially distributed along the brick to impart strength
therein.
[0013] Another object of the invention is to provide a system
having a controller to regulate operation of the system. Parameters
such as speed of conveyer, curing temperature, rotational speed of
the mixer can be adjusted via the controller.
[0014] At least one of the preceding objects is met, in whole or in
part, by the present invention, in which the embodiment of the
present invention describes a geopolymer brick fabrication system
comprising a mixer (100) having a tank (101) which comprises a
closeable bottom outlet (102) and an inner surface coated with
saturated polyester resin that is resistant against corrosive
geopolymeric material for receiving the geopolymer raw material to
be mixed by shaft (103) driven by a spindle motor (104), a moulding
section (200) to receive the mixed geopolymer raw material through
a slanted conveyer (105) upon opening of the closeable outlet (102)
for shaping the mixture under pressure inside a mould (201) to
obtain a geopolymer brick and a curing section (300) having a
moving platform (301) across a curing chamber (302) to
simultaneously cure and transport the brick thereon.
[0015] One skilled in the art will readily appreciate that the
present invention is well adapted to carry out the objects and
obtain the ends and advantages mentioned, as well as those inherent
therein. The embodiments described herein are not intended as
limitations on the scope of the invention as well as not limited to
what are described herein.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 An illustration of the geopolymer brick fabrication
system
DETAILED DESCRIPTION OF THE INVENTION
[0017] This present invention relates to a system to fabricate
geopolymer brick. Raw material of geopolymer is essentially
measured according to ratio in order to customize the brick for a
desired purpose.
[0018] The geopolymer raw material can be a combination of
pozzolanic material, alkaline activator and aggregate. The
pozzolanic material can be any siliceous or siliceous and aluminous
material which is able to react chemically in alkaline condition to
obtain compounds having cementitious properties. Therefore, the
pozzolanic material is essentially substituting the use of cement
in bricks.
[0019] The pozzolanic material used can be of both natural and
artificial material, nevertheless the natural material is favoured
to conserve energy and prevent formation of industrial waste. In
order to conserve natural resources, the material is preferably
obtain from industrial, agricultural, domestic or sewage waste. In
the preferred embodiment of this invention, the pozzolanic material
can be derived from fly ash, volcanic ash, palm oil fly ash or a
combination thereof.
[0020] To provide alkaline condition for chemical reaction or
geopolymerization to occur, alkaline activator can be employed.
Preferably, the alkaline activator is sodium hydroxide, sodium
silicate or a combination thereof. Nevertheless, calcium hydroxide,
potassium hydroxide can also be used in lieu of sodium
hydroxide.
[0021] Aggregates are essentially used as part of the geopolymer
raw material. Preferably, the aggregate is sand, gravel, crushed
stone, slag or a combination thereof.
[0022] In one of the preferred embodiment, a batch of geopolymer
brick composition has pozzolanic material to alkaline activator,
sodium silicate to sodium hydroxide in alkaline activator and
aggregate to pozzolanic materials in a weight ratio of 0.5 to 4:0.5
to 4:2 to 8. The geopolymer brick produced according to the ratio
mentioned can be used to substitute cement brick in construction
industries as a construction material.
[0023] Hereinafter, the geopolymer brick fabrication system is
shown in FIG. 1. Preferably, a batch of geopolymer raw material can
be measured and be fed into the mixer (100) of the system.
[0024] The present invention discloses a geopolymer brick
fabrication system comprising a mixer (100) having a tank (101)
which comprises a closeable bottom outlet (102) and an inner
surface coated with saturated polyester resin that is resistant
against corrosive geopolymeric material for receiving the
geopolymer raw material to be mixed by shaft (103) driven by a
spindle motor (104), a moulding section (200) to receive the mixed
geopolymer raw material through a slanted conveyer (105) upon
opening of the closeable outlet (102) for shaping the mixture under
pressure inside a mould (201) to obtain a geopolymer brick and a
curing section (300) having a moving platform (301) across a curing
chamber (302) to simultaneously cure and transport the brick
thereon.
[0025] Prior to usage, the inner surface of the tank (101) is
preferably coated by saturated polyester resin to sustain a high
alkaline condition provided by the mixture. The resin can be
applied to the surface by powder coating or electrostatic spraying.
Nevertheless, powder coating is favoured to avoid the use of
solvent which is basically required for liquid coating such as a
paint or lacquer. Further, the resin used is preferably chemical
resistance and salt spray resistance. The coating applied
substantially protects the tank from corrosion. In the preferred
embodiment, the tank is having a mixing capacity in a range from 40
to 200 kg for a batch of geopolymer raw material.
[0026] Further, surface of the shaft (103) is preferably coated
with the saturated polyester resin prior to usage.
[0027] Hereinafter, the geopolymer raw material is fed to the mixer
(100) essentially driven by a spindle motor (104) having at least
one shaft. Preferably, a shaft (103) having helical gear is
employed to facilitate the mixing process. In particular, the shaft
can be operated from 2 to 10 Hp under 10 revolution per minute
(rpm) of rotational speed.
[0028] Further, the mixer further comprises a moveable frame
structure (106) which basically imparts mobility to a frame
carrying the mixer (101) and the slanted conveyer (102). The
moveable frame structure (106) essentially comprises rollers
attached at the base. When a force is applied horizontally, the
structure (106) is able to slide away from the direction of the
applied force. In the preferred embodiment, the moveable frame
structure (106) is mounted on a sliding track.
[0029] An essentially homogeneous mixture is obtained from the
mixer (100). The mixture can be released upon opening of the
closeable bottom outlet (102) to reach the slanted conveyer (105).
Subsequently, the slanted conveyer (105) can be brought into
contact with the moulding section (200) via sliding of the movable
frame structure (106).
[0030] The amount of the mixture being delivered to the moulding
section (200) can be determined by controlling opening time of the
closeable outlet (102), speed of the slanted conveyer (105) and
contacting time between the mixture (100) and the moulding section
(200). Preferably, the system in the present invention is having a
controller (303) to regulate the operation mentioned.
[0031] The moulding section (200) essentially comprises a
compressor (203) to apply pressure for pressing. The compressor can
be an air compressor or a hydraulic compressor. A top mould (202)
is attached beneath the compressor to transfer the pressure applied
therein to the mould (201) where geopolymer raw material is
preferably placed.
[0032] The compressor (203) is preferably having a force capacity
of 40 tonne, or 40,000 kg. The geopolymer raw material mixture is
essentially compressed inside the mould (202) to obtain a brick
shape.
[0033] In the preferred embodiment, the moulding section (200) is
having an ejector (204) beneath the mould (201) to release the
brick therefrom. Basically, the ejector can be driven by electric
or hydraulic power to provide an upward vertical force against the
gravity. The force can be used to detach the brick from the mould,
hence releasing an uncured shaped geopolymer brick.
[0034] The system in the present invention further comprising an
extension conveyer (400) between the moulding section (200) and the
curing section (300). The uncured shaped geopolymer brick can be
delivered to the curing section via translational force which is
derived from movement of the frame structure (106).
[0035] In the preferred embodiment, the moving frame structure
(106) essentially brings the slanting conveyer into contact with
the brick formed on the mould base (201) prior to release of
another portion of the geopolymer mixture. Upon contact, the
translational force is transferred onto the brick hence delivering
the brick into the extension conveyer (400).
[0036] The extension conveyer (400) essentially offers a moving
platform for the brick to reach the curing chamber (300).
[0037] Preferably, the curing section (300) comprises a moving
platform (301) and a curing chamber (302) which is essentially a
heater. Preferably, an infrared heater is used. Nevertheless, an
oven can also be utilised.
[0038] An insulated hood (304) having fibre wool can be mounted on
the moving platform (301) to minimize dissipation of heat to the
environment. The moving platform (301) can be a conveyer system
having stainless steel conveyer belt to withstand high temperature
during curing process.
[0039] Hence, the brick enters the curing section (300) and being
cured on the moving platform (301). The brick is being
simultaneously cured and transported along the moving platform
(301) for a certain period depending on the speed of the moving
platform (301). The heater in the curing chamber (302) used is able
to provide a temperature range of 50 to 500.degree. C.
[0040] Hereinafter, the system further comprising a controller
(303) attaching to the curing chamber (302) to regulate operation
of the system. The controller (303) can be used to control
operations such as temperature, speed of conveyer, leveling of
compressor, opening or closure of outlet and movement of the
moveable frame structure. Further, it provides a function that
terminates all operation therein.
[0041] The system further comprising a gravity roller conveyer
(501) connected to receive geopolymer bricks from the curing
section (300). The bricks obtained can be simultaneously cooled and
transported on the gravity roller conveyer (501) that leads to a
collection point for the geopolymer bricks.
* * * * *